Used Vegetable Oil Could Become Aviation Fuel

Scientists from the Institute of Catalysis SB RAS with support from the Russian Science Foundation are working on catalysts for converting used cooking oils into components for environmentally friendly aviation fuel. These sustainable aviation fuel (SAF) technologies are capable of reducing the carbon footprint of air travel significantly without making drastic changes to the existing infrastructure.

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Aviation remains a major source of greenhouse gas emissions: the industry emitted over 940 million tons of CO₂ into the atmosphere in 2024 alone. At the same time, the aviation industry is stepping up the production of fuels from renewable feedstock. Although SAF combustion produces carbon dioxide as well, aggregate emissions across the entire production chain (from feedstock to usage) are almost 80% lower than those of conventional jet fuel. While global SAF production is currently estimated at about 2 million tons per year, major companies expect to increase SAF production to 500 million tons by 2050.

Used edible oils are considered among the most accessible and economically attractive feedstock for SAF. They are cheaper than petroleum feedstock; the global market for edible oils is estimated at about $7 billion. These oils are processed with the HEFA technology, which removes oxygen from fats using hydrogen and converts them into a hydrocarbon mixture. This mixture undergoes cracking and isomerization, which results in feedstock that can be used to produce aviation fuel, diesel, and gasoline.

There are two approaches to the HEFA process. With the classic approach, the reactions are divided into two stages: oxygen is removed to form normal alkanes, after which the fuel’s performance properties are improved. A more modern and cost-effective approach involves a single-stage process in which hydrodeoxygenation, hydroisomerization, and partial hydrocracking occur simultaneously on a single catalyst. It is these types of systems that are the focus of research at the Institute of Catalysis SB RAS.

The scientists are looking into bifunctional catalysts based on nickel and molybdenum which are applied to zeolite-containing carriers. Their goal is to understand how carrier preparation methods and active component application affect the efficiency, selectivity, and reliability of the catalysts.

In the future, these solutions could streamline the production of environmentally friendly aviation fuel and cut its cost significantly.